Synthetic rubber wallet and related methods of manufacture

ABSTRACT

A wallet comprises first and second panels formed of a synthetic rubber material such as neoprene. The first and second panels are stitched together at their edges to form a container having dimensions suiting to receiving cards, such as credit cards or business cards. An opening is formed across a longitudinal direction of the second panel to allow cards to be inserted to and removed from the wallet.

BACKGROUND

The inventive concept relates generally to wallet technology. More particularly, the inventive concept relates to wallets made of a synthetic rubber material such as neoprene and related methods of manufacture and distribution.

Wallets come in many different forms, sizes, and materials. As examples, one can readily purchase wallets made of canvas, leather, plastic, and other forms of textile and non-textile materials. Such wallets are commonly designed to store a variety of small personal items, such as paper money, coins, pictures, credit cards, identification cards. They can also be designed to store bigger items, such as portable electronic devices, checkbooks, and makeup. To accommodate the above or other items, wallets are generally designed with a variety of different pouches, pockets, zippers, velcro fasteners, buttons, and so on.

While many different types of wallets are currently available, new wallets continue to be developed to suit the ever changing preferences and lifestyles of individuals. For instance, in recent years, new simple wallets have been developed to suit the needs of those who carry a few credit or debit cards and little else. At the same time, new complex wallets have also been developed to suit the needs of those who want to carry newer electronic devices or other accessories.

Although a number of simple wallets have been developed, even the simple wallets tend to be fairly expensive, costing ten dollars or more. One reason for the high cost is that the manufacture and distribution of wallets continues to be a somewhat complex and intricate process. The manufacture of even a simple wallet, for instance, may involve intricate stitching of many small components; it may also require expensive machines capable of working on specialized materials, and so on. Additionally, the distribution of the wallets between manufacturers, sellers, and consumers can involve multiple transportation and packing steps that can pile on incremental costs.

The inventors have attempted to address these and other problems of conventional wallets by creating simple new wallet designs using a synthetic rubber material such as neoprene. In conjunction with these new wallet designs, the inventors have also created new ways of manufacturing and distributing wallets.

SUMMARY

According to one embodiment of the inventive concept, a wallet comprises a first panel formed of a synthetic rubber material and having a transverse length and a longitudinal length greater than the transverse length, a second panel formed of a synthetic rubber material and having a transverse length and longitudinal length substantially the same as the first panel, the second panel having outer edges attached to outer edges of the first neoprene panel, and a slit formed in the second neoprene panel along its longitudinal length to create an opening allowing items to be securely inserted between the first and second panels.

In certain embodiments, the edges of the first panel are attached to the edges of the second panel by sewing, and in certain embodiments, the sewn edges of the first and second panels are turned inside the opening of the wallet.

In certain embodiments, the longitudinal length of the first and second panels is within a range of about 90-110 mm, and the transverse length of the first and second panels is within a range of about 75-85 mm.

In certain embodiments, the first and second panels each have rounded corners extending about 15-20 mm from straight edge portions of the first and second panels. In certain embodiments, the synthetic rubber material is neoprene.

In certain embodiments, the wallet further comprises a design pattern imprinted in the first or second panel by melting.

In certain embodiments, the slit has heat-treated inner edges, and in certain embodiments, the slit is a linear slit.

According to another embodiment of the inventive concept, a method of forming a wallet comprises attaching a rectangular shaped first panel formed of a synthetic rubber material to a rectangular shaped second panel formed of a synthetic rubber material, and forming a slit along a longitudinal length of the second panel to create an opening allowing items to be securely inserted between the first and second panels.

In certain embodiments, attaching the first panel to the second panel comprises sewing the outer edges of the first panel to the outer edges of the second panel.

In certain embodiments, the sewing is performed by an automated sewing machine based on pre-programmed sewing instructions.

In certain embodiments, the method further comprises reconfiguring the attached first and second panels such that the sewn outer edges are located inside the opening.

In certain embodiments, the synthetic rubber material is neoprene.

In certain embodiments, the method further comprises inserting the wallet inside a shipping envelope using an automated packaging machine.

According to still another embodiment of the inventive concept, a method of forming a wallet comprises feeding first and second sheets of synthetic rubber material through a tensioning apparatus to an automated sewing machine, operating the sewing machine to attach a portion of the first and second sheets together with a rectangular stitching pattern defining a wallet outline, cutting the first and second sheets along the wallet outline to create a rectangular pouch comprising first and second panels sewn together by the rectangular stitching, and forming a slit along a lengthwise direction of the second panel.

In certain embodiments, the synthetic rubber material is neoprene.

In certain embodiments, cutting the first and second sheets comprises applying laser light to the first and second sheets along the wallet outline.

In certain embodiments, the method further comprises inserting the rectangular pouch with the slit into a shipping envelope using an automated packaging machine.

In certain embodiments, the rectangular pouch has a longitudinal length within a range of about 90-110 mm and a transverse length within a range of about 75-85 mm, and rounded corners; and wherein the slit is located at a distance of about 20-30 mm from a longitudinal edge of the rectangular pouch.

In certain embodiments the edges of the slit are reinforced by oversewing

In certain embodiments the edges of the slit are reinforced by melting

In certain embodiments the edges of the slit are reinforced by the addition of adhesives

In certain embodiments the edges of the slit are reinforced by the addition of synthetic rubber.

In certain embodiments an additional loop of material is incorporated to attach additional articles to the wallet such as keys, lights, or mace.

In certain embodiments the thickness of the neoprene construction material will measure about 0.5-6 mm.

BRIEF DESCRIPTION OF THE DRAWINGS

Selected embodiments of the inventive concept are described below with reference to the accompanying drawings. In the drawings like reference numbers denote like features.

FIGS. 1A and 1B show front and back views of a neoprene wallet in accordance with an embodiment of the inventive concept.

FIGS. 2A and 2B illustrate the dimensions of a neoprene wallet in accordance with an embodiment of the inventive concept.

FIG. 3 shows a perspective view of a neoprene wallet in accordance with an embodiment of the inventive concept.

FIGS. 4A through 4D show perspective views of a neoprene wallet and an example of its use in accordance with an embodiment of the inventive concept.

FIGS. 5A through 5C illustrate a method of manufacturing a neoprene wallet in accordance with an embodiment of the inventive concept.

FIG. 6 illustrates a technique for simultaneously manufacturing multiple wallets in accordance with an embodiment of the inventive concept.

FIGS. 7A and 7B are flow diagrams illustrating different methods of manufacturing a neoprene wallet in accordance with embodiments of the inventive concept.

FIG. 8 is a conceptual diagram illustrating various components that can be used to manufacture and distribute a neoprene wallet in accordance with various embodiments of the inventive concept.

FIG. 9 illustrates various configurations for an opening in a neoprene wallet based in accordance with certain embodiments of the inventive concept.

FIGS. 10A through 10D illustrate different techniques for forming an opening in a neoprene wallet in accordance with various embodiments of the inventive concept.

FIG. 11 illustrates a method of distributing a neoprene wallet in accordance with an embodiment of the inventive concept.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments of the inventive concept will now be described with reference to the attached drawings. These embodiments are provided as teaching examples and should not be construed to limit the scope of the inventive concept as defined by the claims.

In general, the described embodiments relate to wallets made of a synthetic rubber material such as neoprene. Due to their simple design, these wallets may be produced at a relatively low cost, and they may be susceptible to extremely efficient manufacturing and distribution processes. For instance, in some embodiments, synthetic rubber wallets may be manufactured using an automatic process involving a simple tensioning apparatus, an automated sewing machine, and a laser cutting apparatus. In the described embodiments, the wallets are made of neoprene, which is a commonly available synthetic rubber fabric. The embodiments are not limited to this material, however, but could be made of other synthetic rubber materials available to those skilled in the art.

The described embodiments may also provide various benefits to users due to the simple design of the wallets and the materials involved. As examples, the described wallets may occupy less pocket space compared with many conventional wallets, they may be washed in typical washing machines, and they may float in water, to name but a few potential benefits.

FIG. 1 shows an example of a neoprene wallet 100 in accordance with an embodiment of the inventive concept. In particular, FIG. 1A shows a front view of wallet 100 and FIG. 1B shows a back view of neoprene wallet 100.

Referring to FIGS. 1A and 1B, wallet 100 comprises a first panel 105, a second panel 110, and a slit 120 formed in second panel 110. First and second panels 105 and 110 are each formed of a rectangular sheet of neoprene having rounded corners and a width longer than its height. Slit 120 is located along the widthwise, or longitudinal direction of second panel 110. Although slit 120 is formed in a simple straight line in this embodiment, it could alternatively be formed in a nonlinear fashion, e.g., in a V-shape or a curved shape.

First and second panels 105 are typically formed of conventional neoprene sheets having a few millimeters of thickness. In some embodiments, these panels can be modified by the addition of coverings or designs. For instance, the panels could be bound or fused to certain textile or polymer materials, they could be heat-branded to include distinctive markings or logos, they could be died with different colors, or they could be embroidered, to name but a few possible variations. The panels could also be modified by the addition of embedded, interwoven, or interleaved features, such as embedded radio-frequency identification (RFID) tags or other electronic elements, or layered sheets of additional material.

First and second panels 105 and 110 are attached to each other by stitching 115, which can be formed by any of several types of thread, yarn, or other stitching elements. In alternative embodiments, first and second panels 105 and 110 can also be attached using other techniques, such as gluing, melting, stapling, or any of several other techniques available to those skilled in the art.

FIG. 2 illustrates example dimensions of wallet 100 in accordance with an embodiment of the inventive concept. In particular, FIG. 2A illustrates example dimensions for first panel 105 of FIG. 1, and FIG. 2B illustrates example dimensions for second panel 110 of FIG. 1.

Referring to FIG. 2A, first panel 105 has a height of approximately 80 mm and a width of approximately 100 mm. Widthwise, or longitudinal, edges of first panel 105 have straight portions spanning 80 mm between the rounded corners, and heightwise, or transverse, edges of first panel 105 have straight portions spanning approximately 60 mm between the rounded corners.

Referring to FIG. 2B, second panel 110 has substantially the same outer dimensions as first panel 105. In addition, slit 120 is formed across the width of second panel 110 approximately 25 mm from an upper widthwise edge of second panel 110.

FIG. 3 shows a perspective view illustrating an example thickness of wallet 100 in accordance with an embodiment of the inventive concept. As illustrated in FIG. 3, the overall thickness of first and second panels 105 and 110 is approximately 6 mm. Thus, the individual thickness of each panel is approximately 3 mm. In alternative embodiments, the thickness of panels 105 and 110 can be modified to be greater or less than 3 mm. For instance, in certain embodiments, the thickness of each panel can be adjusted to measure between 0.5 and 6 mm. Additionally, first and second panels 105 and 110 are not restricted to having the same thickness.

In the examples of FIGS. 2 and 3, the dimensions of wallet 100 can allow it to accommodate common forms of cards, such as credit cards, business cards, identification cards, and so on. It can also accommodate other commonly carried items, such as folded bills, coins checks, and others.

FIGS. 4A through 4D show different perspective views of neoprene wallet 100 and an example of its use in accordance with an embodiment of the inventive concept. In the example of FIGS. 4A through 4D, wallet 100 is turned inside-out relative to the example of FIG. 1, so that stitching 115 borders on an outer extreme of wallet 100 and the seams are turned inward.

FIG. 4A shows an example of wallet 100 in a closed position. FIG. 4B shows an example of wallet 100 in a position exposing an opening 125 where articles can be inserted.

FIG. 4C illustrates an identification card 130 inserted in opening 125, and FIG. 4D illustrates wallet 100 in the closed position with identification card 130 inside. In various embodiments, wallet 100 can accommodate several cards at a time based on the dimensions and other properties of wallet 100, such as the elasticity of panels 105 and 110.

FIG. 4D also shows two possible modifications of wallet 100, including the addition of a loop 150 for attaching articles, such as keys, lights, or mace, and the addition of a hole 160 for attaching a chain or other articles. Loop 150 can be made of any of several materials, such as rubber, cloth, or plastic. Hole 160 typically penetrates both first and second panels 105 and can be reinforced with any of several materials, such as metal, plastic, or oversewing.

FIGS. 5A through 5C illustrate a method of manufacturing a neoprene wallet in accordance with an embodiment of the inventive concept.

Referring to FIG. 5A, the method begins with independent first and second panels 105 and 110. These panels are placed together and aligned to allow stitching to occur. In various alternative embodiments, these panels can be cut from one or more larger sheets of neoprene or other synthetic rubber material, or they can be manufactured or supplied in the size required to manufacture wallet 100.

Referring to FIG. 5B, first and second panels 105 and 110 are stitched together with stitching 115. This can be accomplished, for instance, by hand stitching or by an automated sewing machine. Various automated sewing machines are currently available that allow sewing designs to be programmed and automatically applied to a supplied material.

Referring to FIG. 5C, slit 120 is formed in second panel 110 to produce an upper portion 110A and a lower portion 110B. Slit 120 can be formed, for instance, by cutting second panel 110 with a sharp object such as a razor blade or scissors, a heat element such as a laser, or with a high pressure water jet as will be described in further detail with reference to FIG. 10. Although the method of FIG. 5 forms slit 120 after aligning panels 105 and 110 and forming stitching 115, slit 120 could alternatively be formed prior to either the aligning or the stitching. Moreover, in certain embodiments, second panel 110 can be formed by separately attaching upper and lower portions 110A and 110B to first panel 105.

FIG. 6 illustrates a technique for simultaneously manufacturing multiple wallets in accordance with an embodiment of the inventive concept.

Referring to FIG. 6, two large sheets of neoprene 605 and 610 are arranged next to each other and multiple wallets 620 are formed by performing stitching 615 on the sheets. The stitching of wallets 620 is typically performed by an automated sewing machine that has been programmed to form stitching 615 in accordance with a stored pattern. These sheets can be held in a proper position using a tensioning apparatus, as will be described in further detail with reference to FIG. 8.

After the stitching has been performed, wallets 620 are separated from each other by a separation technique such as cutting or burning, which may involve technologies such as razor or laser cutters, or chemical burning techniques. Following the separation of wallets 620, an opening or slit can be formed in each wallet, similar to slit 120 of FIG. 1.

FIGS. 7A and 7B are flow diagrams illustrating different methods of manufacturing a neoprene wallet in accordance with selected embodiments of the inventive concept. These methods are similar to those described above with reference to FIGS. 5 and 6. In particular, FIG. 7A illustrates a method in which large panels of neoprene are sewn to form multiple wallets (705A), followed by creation of an opening in each wallet using a technique such as cutting (710A), followed by separation of the large panels into the multiple wallets (715A). FIG. 7B illustrates a method in which sheets of neoprene are cut into wallet-sized panels (705B), followed by sewing of two panels together (710B), and then forming an opening in one of the panels to allow articles to be inserted into an enclosure formed by the sewn-together panels (715B).

FIG. 8 is a conceptual diagram illustrating various components that can be used to manufacture and distribute a neoprene wallet in accordance with various embodiments of the inventive concept.

Referring to FIG. 8, a manufacturing system 800 for forming simple neoprene wallets comprises a tensioning unit 850, a sewing unit 860, a cutting unit 870, and a packaging unit 880. Tensioning unit 850 comprises spools 801 and 802 for feeding neoprene sheets 805 and 810 through rollers 803 and 804. Sewing unit 860 typically comprises an automated or robotic sewing machine that sews wallets-sized portions together in sheets 805 and 810 in coordination with the movement of sheets 805 and 810 by tensioning unit 850. In various embodiments, tensioning unit 850 can feed the sheets to sewing unit 860 in discrete units at separate intervals with intervening stops, or it can feed the sheets on a continual basis, e.g., at a predetermined rate. Cutting unit 870 comprises a mechanical and/or laser cutting device for separating the sewn sheets 805 and 810 into individual wallet-sized units, and forming openings in the respective units. Packaging unit 880 comprises elements for packaging the wallets and/or preparing them for shipping. For instance, in some embodiments, packaging unit 880 comprises an envelope stuffer or other automatic packaging apparatus for inserting wallets into envelopes, boxes or other shipping instruments. Packaging unit 880 may further comprise elements for automatically applying postage to the packaging or shipping instruments.

In certain embodiments, manufacturing system 800 can be operatively connected to a server to control interoperation of elements 850 through 880. For instance, the server could control the timing of tensioning unit 850, sewing unit 860, and cutting unit 870 to ensure proper flow of manufacturing. Such control may be purely top-down, where the server imposes a predetermined timing scheme on the elements of system 800, or it may involve bottom-up aspects, where the elements of system 800 provide feedback to determine the flow of other elements. As one example of bottom-up control, sewing unit 860 may provide a ready or busy signal to the server to indicate whether it is ready to receive more material through tensioning unit 850. The server can control tensioning unit 850 to feed more material to sewing unit 860 based on the ready or busy signal.

FIG. 9 illustrates various example configurations of slit 120 in neoprene wallet 100. These different configurations can be achieved, for instance, by using different finishing or formation techniques. The different configurations of slit 120 are labeled 900A through 900F.

Configuration 900A is formed by melting through second panel 110, leaving melted portions on the inner edges of the slit or opening, as indicated by relatively thick dark lines. The melting process, can be performed, for instance, by a laser or heated metal. Configuration 900B is formed by first cutting second panel 110 to form slit 120 and then adding edge stitching, or oversewing, to the inner edges of slit 120, as indicated by hatched lines. Configuration 900C is formed by making a straight inward cut, as contrasted with angled cuts as in configurations 900D through 900F. The different types of cuts in configurations 900C through 900F provide various potential tradeoffs, such as ease of opening, prevention of wear and tear, and appearance. Like many other types of cuts, the cuts in configurations 900C through 900F can be made using any available cutting technique.

In some of the above configurations, finishing techniques can be applied to the edges of slit 120 to produce smooth or sturdy edges. Such finishing techniques could include, for instance, melting or otherwise heat-treating inner edges of slit 120 that have been exposed by cutting, or trimming edge portions with a fine trimming tool. Additionally, in various alternative embodiments, the edges of the slit can be reinforced by melting, the addition of adhesives, or the addition of further synthetic rubber.

In addition, or as an alternative to the above finishing techniques, the edges can also be attached to a magnetic material, such as flexible magnet strip or a set of individual magnets. These materials can be used to maintain slit 120 in a closed position. The magnetic material can be attached to second panel 110 by, e.g., an adhesive backing, sewing, or glue. Alternatively, the magnetic material could also be embedded in a portion of second panel 110.

FIGS. 10A through 10D illustrate selected examples of cutting techniques for forming openings such as those illustrated in FIG. 9. For instance, as indicated by FIG. 10A, the openings can be formed using a conventional cutting technology 1020 such as scissors, razor blades, or other sharp cutting tools that slice or move across panel 110. As indicated by FIG. 10B, the openings can be formed using a clamping device 1025 to melt or cut panel 110 by direct contact and/or pressure applied to opposing sides. As indicated by FIG. 10C, the openings can be formed by a laser cutting device applied to panel 110. To prevent the laser from damaging panel 105, a back plate 1030 can be inserted between panels 105 and 110 while the laser performs the cutting. Similarly, in the embodiment of FIG. 10D, the openings are formed by a focused high pressure water jet that penetrates second panel 110 by force.

In the examples of FIG. 10, slit 120 is formed before panels 105 and 110 are stitched together. In alternative embodiments, however, slit 120 can be formed after one or more sides of panels 105 and 110 are stitched together. For instance, the cutting technology 1020 can be used to puncture and cut across second panel 110 after it is sewn to first panel 105. Similarly, the laser or water jet can cut through second panel 110 after it is sewn to first panel 105 with back plate 1030 inserted inside. Back plate 1030 can then be removed through the opening formed in second panel 110.

FIG. 11 illustrates a method of distributing a neoprene wallet in accordance with an embodiment of the inventive concept. In this embodiment, wallet 100 is distributed by mail in an envelope 1110. Wallet 100 is inserted in the envelope in the configuration with stitching on the outside so that first panel 105 lies flush against second panel 110, as in FIGS. 1 through 3. This renders the wallet more compact for easier shipping. Wallet 100 can be sent with instructions 1105 indicating that the configuration should be changed to that of FIG. 4 with the seams inside for use.

The method of FIG. 11 comprises inserting wallet 100 and instructions 1105 into envelope 1110 (1101), sealing the envelope and applying postage for shipping (1102), and subsequently shipping the wallet. Due to compact size and light weight of wallet 100, it can typically be shipped with minimal postage in a small unit, providing an efficient and cost effective means of distribution.

The foregoing is illustrative of embodiments and is not to be construed as limiting thereof. Although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in the embodiments without materially departing from the novel teachings and advantages of the inventive concept. Accordingly, all such modifications are intended to be included within the scope of the inventive concept as defined in the claims. 

1. A wallet, comprising: a first panel formed of a synthetic rubber material and having a transverse length and a longitudinal length greater than the transverse length; a second panel formed of a synthetic rubber material and having a transverse length and longitudinal length substantially the same as the first panel, the second panel having outer edges attached to outer edges of the first panel; and a slit formed in the second panel along its longitudinal length to create an opening allowing items to be securely inserted between the first and second panels.
 2. The wallet of claim 1, wherein the edges of the first panel are attached to the edges of the second panel by sewing.
 3. The wallet of claim 1, further comprising a loop attached to the outer edges of the first and second panels.
 4. The wallet of claim 1, wherein the longitudinal length of the first and second panels is within a range of about 90-110 mm, and the transverse length of the first and second panels is within a range of about 75-85 mm.
 5. The wallet of claim 1, wherein the first and second panels each have rounded corners extending about 15-20 mm from straight edge portions of the first and second panels.
 6. The wallet of claim 1, wherein the synthetic rubber material is neoprene.
 7. The wallet of claim 1, further comprising a design pattern imprinted in the first or second panel by melting.
 8. The wallet of claim 1, wherein the slit has heat-treated inner edges.
 9. The wallet of claim 2, wherein the sewn edges of the first and second panels are turned inside the opening of the wallet.
 10. A method of forming a wallet, comprising: attaching a rectangular shaped first panel formed of a synthetic rubber material to a rectangular shaped second panel formed of a synthetic rubber material; and forming a slit along a longitudinal length of the second panel to create an opening allowing items to be securely inserted between the first and second panels.
 11. The method of claim 10, wherein attaching the first panel to the second panel comprises sewing the outer edges of the first panel to the outer edges of the second panel.
 12. The method of claim 11, wherein the sewing is performed by an automated sewing machine based on pre-programmed sewing instructions.
 13. The method of claim 11, further comprising: reconfiguring the attached first and second panels such that the sewn outer edges are located inside the opening.
 14. The method of claim 10, wherein the synthetic rubber material is neoprene.
 15. The method of claim 10, further comprising: inserting the wallet inside a shipping envelope using an automated packaging machine.
 16. A method of forming a wallet, comprising: feeding first and second sheets of synthetic rubber material through a tensioning apparatus to an automated sewing machine; operating the sewing machine to attach a portion of the first and second sheets together with a rectangular stitching pattern defining a wallet outline; cutting the first and second sheets along the wallet outline to create a rectangular pouch comprising first and second panels sewn together by the rectangular stitching; and forming a slit along a lengthwise direction of the second panel.
 17. The method of claim 16, wherein the synthetic rubber material is neoprene.
 18. The method of claim 16, wherein cutting the first and second sheets comprises applying laser light to the first and second sheets along the wallet outline.
 19. The method of claim 16, further comprising: inserting the rectangular pouch with the slit into a shipping envelope using an automated packaging machine.
 20. The method of claim 16, wherein the rectangular pouch has a longitudinal length within a range of about 90-110 mm and a transverse length within a range of about 75-85 mm, and rounded corners; and wherein the slit is located at a distance of about 20-30 mm from a longitudinal edge of the rectangular pouch. 